CN1196245C - Stator for external rotor motor - Google Patents

Abstract

The present invention aims to produce a stator of outer rotor motor with adequate rustproof effect for ensuring the motor's excellent performance and simplifying the process. The outer rotor motor (1) for driving the fan of a refrigerator consists of a casing (2), a rear bearing combination (3), a stator (4), a front bearing combination (5), and a rotary fan rotor (7). The rear bearing combination (3) is installed on the casing (2). The stator (4) is installed on the rear bearing combination (3). The front bearing combination (5) is installed on the stator (4). The rotary fan rotor (7) is formed in one mold and is supported on the turning axle (6) of the two bearing combinations (3 and 5). Separated by an insulator (30), a winding set (31) is wound in the stator core (17) and, formed in one mold. A terminal board (32) with a wire connector (18) is installed on the winding set (31). Then, a casting layer (33) formed by thermoplastic resins is used to cast all parts, except the center hole (17a) of the stator core (17), in one mold into the stator (4). Since, the casting layer (33) wraps the periphery of the stator core (17) as a thin layer, an adequate rustproof effect can be obtained.

Description

The stator of external-rotor motor

The present invention relates to the stator of external-rotor motor that the peripheral part of stator core and coil are formed with the embossed plies mold pressing.

The fans drive of refrigerator for example with external-rotor motor on, in order to adapt to dewfall environment (wet environment), partly carry out resin-molded (seeing that Japanese Utility Model discloses 1982-139263 number) to the stator coil except the stator core outer peripheral face.In this occasion, be to carry out resin-molded with the strong thermosetting resins such as unsaturated polyester (UP) of resistance to sudden heating, this thermosetting resin is poor because of flowability, can not form the thin-walled embossed plies at the outer peripheral face of stator core, therefore, also to be coated with one deck rust inhibitor thinly at the stator core outer peripheral face that the resin that is not molded covers.

Yet, when adopting said structure, owing to be coated with rust inhibitor at the outer peripheral face of stator core, so assembling procedure is many, the manufacturing cost height.To this, once imagination as the outer peripheral face of stator core is also carried out mold pressing in the lump with mold pressing resin, just no longer need to be coated with the operation of rust inhibitor, but as mentioned above, if form embossed plies at the outer peripheral face of stator core with thermosetting resin, the heavy wall of just having to make, like this, will correspondingly increase with gap between rotor, the characteristic (efficient) of motor is worsened.

In view of the foregoing, the object of the present invention is to provide the stator of a kind of superperformance that has good rust-proof effect and can guarantee motor, the simple external-rotor motor of while manufacturing process.

Conventional art carries out use the strong thermosetting resin of thermal endurance and resistance to sudden heating usually, and on external-rotor motor, the peripheral part of the stator core relative with stator being not carry out mold pressing when resin-molded at the stator coil with motor.The inventor then attempts using thermoplastic resin, the part of the peripheral part that comprises stator core is carried out whole resin-molded, confirm to obtain enough thermal endurances and resistance to sudden heating like this, and can be formed uniformly extremely thin embossed plies at the peripheral part of stator core, can guarantee very high motor efficiency, realize the present invention therefrom.

Promptly, the characteristics of the stator of external-rotor motor of the present invention are, have: stator core, be wound on the coil in this stator core across insulator, be located on the aforementioned dielectric body and connect the pin of aforementioned end winding, cardinal extremity and aforementioned pin are electrically connected and have terminal board with outside connecting connector portion at front end, the embossed plies that the thermoplastic resin that the peripheral part and the terminal board base end part of aforementioned coil and stator core carried out integral die constitutes etc., and forming when being arranged on die forming on the outer peripheral face of periphery wall portion of one with insulator and the inner face butt of finishing die, can prevent the protuberance (invention of technical scheme 1) that periphery wall portion is out of shape because of the resin injection pressure.

Adopt such scheme,,, need not to be coated with in addition operations such as rust inhibitor so, also have sufficient rust-proof effect even under wet environment, use because the peripheral part of the embossed plies stator core that constitutes with thermoplastic resin has also covered.In this occasion,, can do the embossed plies of stator core peripheral part extremely thin by using thermoplastic resin.And have enough thermal endurances and a resistance to sudden heating.And, because the base end part of the peripheral part of coil and stator core and terminal board by mold pressing integrally, so stator is convenient to operation, can improve efficiency of assembling.Self-evident, also can utilize embossed plies to protect coil and raising insulating properties and mechanical strength.And owing to protuberance is set forming on the outer peripheral face of periphery wall portion of one with insulator, therefore when die forming protuberance just with the inner face butt of finishing die, thereby can prevent that periphery wall portion is out of shape because of the resin injection pressure.

In this occasion, the thermoplastic resin that aforementioned dielectric body and terminal board can constitute with the basic material with the same kind of embossed plies is made (invention of technical scheme 2).Like this, when forming embossed plies, constitute the resin of embossed plies and the easy heat fusing in surface of insulator and terminal board, making can be bonding well between embossed plies and insulator and the terminal board, their coefficient of linear expansion is identical simultaneously, so embossed plies, insulator and terminal board three can form an integral body securely.

In addition, embossed plies is shaped with finishing die, for the peripheral part in stator core forms very thin embossed plies, requires to have good flowability as the resin of material.For this reason, in basic material, add the elastomer (invention of technical scheme 3) of rubber series, then can obtain the high fluidity of material if constitute the thermoplastic resin of embossed plies.In addition, when being used for the fan motor of refrigerator for example, basic material preferably uses PBT (polybutadiene terephthalate) or PPS resistance to sudden heating excellent material such as (polyphenylene sulfides).

And, if the position of injecting the inlet of resin during the formation embossed plies is located at the mid portion (invention of technical scheme 4) of the adjacent dentate body of stator core fluting portion, then resin flows to the end face portion of an opposite side with inlet of stator core easily, the resin injection pressure can not directly act on coil simultaneously, can prevent to damage coil.

In this occasion,, then can prevent to damage connecting line effectively if make the connecting line of coil be positioned at the end difference (invention of technical scheme 5) that forms minor diameter on the insulator at the stator core end face at the end face with inlet position opposite one side of stator core.

Perhaps, also the position of the inlet of embossed plies can be located at go up facial (invention of technical scheme 6) of terminal board, like this, the resin injection pressure just directly acts on terminal board, can prevent to damage coil effectively.

But, if blocked up in the embossed plies of stator core peripheral part formation, then stator core and gap between rotor can increase, and make the inefficiency of motor, on the contrary, if thin excessively, can reduce resistance to sudden heating again.Therefore, research according to the inventor, the embossed plies thickness of stator core peripheral part is 3～9% (inventions of technical scheme 7) of the dentate body magnetic pole piece width dimensions of stator core preferably, and the gauge that obtains like this can satisfy motor efficiency and resistance to sudden heating both sides' requirement.

In addition,, make embossed plies form uniform face (invention of technical scheme 8), like this, can constitute the embossed plies of stator core peripheral part equably, can improve resistance to sudden heating at the peripheral part of stator core by remedy the shrinkage cavity of fluting portion with finishing die.

In addition, also the outer circumferential surface section of the embossed plies end face from stator core can be prolonged after the diameter reduction slightly vertically, make parting line be positioned at the outer peripheral face (invention of technical scheme 9) of this extension simultaneously, parting line just can not appear at the embossed plies of stator core peripheral part like this, can prevent its harmful effect to resistance to sudden heating etc.

Can also make above-mentioned insulator and the periphery wall portion of standing on the coil end periphery form one, the height dimension with this periphery wall portion is set in below 3 times of gauge (invention of technical scheme 10) simultaneously.Like this, the winding operation efficient of coil improves in available periphery wall portion, simultaneously because of periphery wall portion relatively its height dimension have certain thickness, can prevent the distortion that the resin injection pressure causes.

Here, can be by being that conductor that the die-cut back of the metallic plate of plating face forms inserts to be shaped and constitutes aforementioned terminal board with the plate face, the leading section of this conductor becomes the connector pin in connector portion, but the rust-preventing characteristic of conductor section is poor.For this reason, 2 kinks can be set on conductor, and the plate face turned round at these 2 kinks turn 90 degrees (invention of technical scheme 11).Like this, just the contact-making surface of the connector pin plating face as conductor can be able to be prevented the bad baneful influence that waits of energising that gets rusty and cause because of connector pin section.

It below is simple declaration to accompanying drawing.

Fig. 1 is the stator stereogram of one embodiment of the invention.

Fig. 2 is the stereogram before the formation embossed plies on stator.

Fig. 3 is the longitudinal section of motor.

Fig. 4 forms the preceding stereogram of seeing stator from the below of embossed plies.

Fig. 5 forms the preceding stator longitudinal section of embossed plies.

Fig. 6 forms the preceding cross-sectional vertical view of stator of embossed plies.

Fig. 7 is the top vertical profile end view (a) and the front view (b) of insulator.

Fig. 8 is the cross-sectional vertical view of dentate body leading section.

Fig. 9 represents to concern between the embossed plies thickness of stator core peripheral part and resistance to sudden heating and the motor efficiency.

Figure 10 is the vertical view (a) and the end view (b) of terminal board conductor fore-end.

Figure 11 is pack into the local cross-sectional vertical view of state behind the finishing die of expression stator core.

Figure 12 is the figure corresponding with Fig. 7 of other embodiments of the invention.

Below in conjunction with description of drawings example of the present invention.

Illustrate that below in conjunction with Fig. 1～Figure 11 fan of refrigerator of the present invention drives an embodiment (corresponding with technical scheme 1,2,3,4,5,7,8,9,11) of the external-rotor motor of usefulness.Wherein Fig. 3 represents the overall structure of the external-rotor motor (fan motor) 1 of present embodiment.This motor 1 is no sensor type DC brushless motor.

This motor 1 roughly by housing 2, be installed in rear bearings assembly 3 on this housing 2, be installed in the present embodiment on this rear bearings assembly 3 stator 4, be installed in front axle bearing assembly 5 on this stator 4, have the rotating shaft 6 that is rotatably freely supported on aforementioned two bearing assemblies 3 and 5 and constitute with fan-shaped all-in-one-piece rotor 7.

Its middle shell 2 usefulness for example plastics such as PBT constitute, and form unlimited slim roughly cylindric of trailing flank (right flank among Fig. 3), and the central part at its front wall portion forms circular port 2a simultaneously.In addition, near the leading flank periphery of front wall portion, form the concave part 2b of ring-type, for example form forwards 3 engaging pawl 2c (only illustrating 1 among the figure) that extend in (left side among the figure) with the intervals of 120 degree at the peripheral part of housing 2.Also the peripheral part at this housing 2 for example is provided with 4 pillars 8 (part only is shown among the figure) that extend along the radiation direction integratedly with the interval of 90 degree, is provided with not shown bellmouth integratedly at the peripheral part of these pillars 8.

In addition, aforementioned rear bearings assembly 3 is provided with the bearing 10 that is made of spherical sintering metal in the carriage 9 that for example is made of galvanized steel plain sheet.Aforementioned bracket 9 has the slim cylindric principal part that opens wide from trailing flank (left the figure) protrusion pipe 9a of portion of extending integratedly forwards, forms hole 9b for aforementioned rotating shaft 6 perforations at this leading section that protrudes pipe 9a of portion.In this carriage 9, aforementioned bearings 10 is being pressed by bearing cap 11 and spring 12, is provided with simultaneously to contain malthoid 13,14.In addition, the lid member 15 that the trailing flank peristome of carriage 9 is used such as galvanized steel plain sheet constitutes stops up, and is provided with the thrust plate 16 of the front end that bears aforementioned rotating shaft 6 at the inner face central part of this lid member 15.

This rear bearings assembly 3 closely embeds in the aforementioned housing 2 from rear side, and at this moment, the protrusion pipe 9a of portion of carriage 9 passes circular port 2a and forwards stretches out.In addition,, also form a plurality of protuberances, protrude the pipe 9a of portion this protuberance is pressed to such an extent that the state of distortion is pressed at the inner peripheral surface of aforementioned circle hole 2a though be not shown specifically among the figure.In addition, the end edge portion at the principal part of carriage 9 forms so-called burr laterally, the nip inner peripheral surface of housing 2 of these burr.

In addition, stator former 4 is provided with stator core 17 as described later, and this stator core 17 is provided with the centre bore 17a of perforation vertically, along the circumferential direction forms 3 protuberance (see figure 6)s at the inner peripheral surface of aforementioned centre bore 17a.Like this, by with the protrusion pipe 9a of portion of aforementioned bracket 9 to be pressed into centre bore 17a latter half of that state is intercalated in stator core 17, just make rear bearings assembly 3 and stator 4 clip housing 2 and fix from both sides.In this occasion, by being pressed between the metal, just can make things convenient for and, and dungeon is firmly fixed without acceptance of persons exactly to axle center (centering).At this moment, the below is arranged on connector portion 18 on the stator 4 with extending and is positioned at pillar 8 position overlapped with 1 (downwards) in figure.

In addition, aforementioned front axle bearing assembly 5 has the structure roughly the same with aforementioned rear bearings assembly 3, the bearing 20, bearing cap 21, the spring 22 that have the carriage 19 that protrudes the pipe 19a of portion, be made of spherical sintering metal is set, contains malthoid 23 and 24 and lid member 25.In this occasion, be that with rear bearings assembly 3 differences be formed centrally peristome 25a in aforementioned cover member 25, the aforementioned in addition protrusion pipe 19a of portion is shorter.

This front axle bearing assembly 5 is being fixed on the stator 4 with the centre bore 17a first half that is pressed into state insertion stator core 17 with above-mentioned rear bearings assembly 3 rightabouts by the protrusion pipe 19a of portion with aforementioned bracket 19.In this occasion, also be by being pressed between the metal, easily exactly to the axle center, dungeon is firmly fixed without acceptance of persons.At this moment, in aforementioned centre bore 17a, between the front end face of aforementioned protrusion pipe 9a of portion and the protrusion pipe 19a of portion, be provided with anticreep member 26.These anticreep member 26 usefulness for example nylon 6 are done circlewise, have the function that prevents that rotating shaft 6 from deviating from described later.

And aforementioned rotor 7 is made of the fan hub portion 29 of for example PBT system of the rotor yoke iron 27 of the unlimited cylindric galvanized steel plain sheet system of rear end face, for example 12 utmost points (6 pairs) rotor magnet 28 that is installed in these rotor yoke iron 27 inner peripheral surfaces, aforementioned rotor yoke iron 27 peripheral parts of covering.In addition, though not shown among the figure, form 4 or 3 fans (wind feeding blades) at the peripheral part of fan hub portion 29.

Aforementioned rotating shaft 6 for example is made up of SUS, and its middle part is provided with minor diameter 6a integratedly.The base end part of this rotating shaft 6 (leading section) is connected with the central part of aforementioned rotor yoke iron 27.In addition, aforementioned fan hub portion 29 is shaped and rotor yoke iron 27 forms one by inserting, the part of its material links to each other by the hole 27a that forms on rotor yoke iron 27, is positioned at inner face one side of yoke 27 end faces with such state, around the covering rotating shaft 6.The rotor 7 following assemblings of said structure, promptly, rotating shaft 6 is pressed into bearing 20 after the peristome 25a of the lid member 25 of aforementioned front axle bearing assembly 5 inserts, and further inserts to the depths, in the bearing 10 that makes its front end at rear bearings assembly 3 with thrust plate 16 butts.Like this, rotor 7 just is rotatably supported in 2 bearings 20 and 10, and relative across minimum gap between rotor magnet 28 and the stator former 4.

In this occasion, because bearing the 20, the 10th, constitute by the spherical metal of automatic aligning structure, so can be accurately with rotating shaft 6 and then with 7 pairs of axle center of rotor.In addition, at this moment to be limits strut the limit with the peristome of anticreep member 26 to rotating shaft 6 inserts, and after having assembled rotor 7, anticreep member 26 just becomes the state chimeric with the minor diameter 6a of rotating shaft 6, therefore in case assembling finishes, just can utilize anticreep member 26 to prevent that rotating shaft 6 from deviating from.

Below describe the structure of the stator 4 of present embodiment in detail.Fig. 1 represents the outward appearance of stator 4, the state before the formation embossed plies of expression such as Fig. 2, Fig. 4, Fig. 5 stator 4.In addition, stator 4 rear sides (right side) in the presentation graphs 3 such as these Fig. 1, Fig. 2, Fig. 5 are the state of (axially as above-below direction) upwards, below for simplicity, Fig. 1, Fig. 2, above-below direction shown in Figure 5 are illustrated as the above-below direction of stator 4.

This stator 4 by the three-phase coil 31 of stator former iron core 17, insulator 30, star-star connection, be provided with the terminal board 32 of aforementioned connector portion 18 integratedly, the embossed plies 33 that forms with thermoplastic resin etc. constitutes.Wherein stator core 17 be with steel plate in axial stacked formation, shown in Fig. 6 waits, be provided with 9 dentate body 17d in the periphery of yoke 17c cylindraceous.The interior perimembranous of aforementioned yoke 17c is as aforementioned centre bore 17a.In addition, the leading section at each root dentate body 17d is provided with the magnetic pole piece 17e of expansion along the circumferential direction.

Aforementioned dielectric body 30 is made of the formed products that is basic material with PBT (polybutadiene terephthalate), contains the thermoplastic resin of a small amount of (for example 15%) glass ingredient in this occasion.This insulator 30 covers into thin wall shape along the inner face in stator former 17 each slit unshakable in one's determination, simultaneously as Fig. 2, Fig. 4, Fig. 5, shown in Figure 7, in interior Monday of side, be provided with cylindric 30a, the 30b that erects vertically integratedly from the upper and lower surface of the yoke 17c of stator core 17.

Also Monday, side was provided with the 30c of periphery wall portion up and down that is erected in each dentate body 17d (magnetic pole piece 17e) to this insulator 30 integratedly outside.In addition, present embodiment such as Fig. 4, shown in Figure 7, outside aforementioned each 30c of periphery wall portion Monday side face on form the protuberance 30d that extends longitudinally.This protuberance 30d more protrudes the roughly size of Pw to peripheral direction than the lateral surface of stator core 17 (magnetic pole piece 17e) shown in Fig. 7 (a).

And, on cylindric 30a of this side above insulator 30, as shown in Figure 2,3 pins 34 that each end connected of the energising side of three-phase coil 31 stretch out upward with comparatively approaching state, on the position of leaving this place slightly, the pin that the end connected 35 of the common side of each coil 31 still is mounted to the state that stretches out upward simultaneously.

On the other hand, below a side cylindric 30b as shown in Figure 4, be located at the end face of stator core 17 with smaller diameter, so just form end difference 30e.Also have, near one one of the periphery wall 30c the pin 34 of insulator 30 tops one side is provided with the claw 30f (seeing Fig. 3, Fig. 5) of fixed terminal platform 32 usefulness.In addition, though be not shown specifically among the figure, these insulator 30 its tangible above-below directions (axially) are divided into 2 parts, they are embedded from above-below direction be installed in the stator core 17.

The outside of the insulator 30 of aforementioned coil 31 on each dentate body 17d of stator core 17.At this moment, the end of each phase coil 31 is connected with pin 34,35.And, as shown in Figure 4, the connecting line 31a of coil 31 below stator core 17 side (side opposite) with pin 34,35 by end difference 30e.

Aforementioned terminal board 32 stretches out to peripheral direction (right-hand Fig. 5) from the principal part of base end part one side that is electrically connected with aforementioned 3 pins 34, while is provided with bulging upward integratedly and has the femal type connector portion 18 of certain altitude, and shown in Fig. 3, Fig. 5 etc., this occasion is to be basic material with PBT, to contain among the pedestal 32a that the thermoplastic resin of more (for example 30%) glass ingredient constitutes 3 conductors 36 are inserted and be shaped.These conductors 36 are made after electroplating steel plate is cut off, and form in base end part one side (principal part one side) to have the tabular of certain width, are provided with the hole 36a (see figure 5) that connects for aforementioned pin 34 simultaneously.When pedestal 32a is set, make this hole 36a partly expose conductor 36.

These conductors 36 extend towards connector portion 18, and its leading section reaches in the shell of connector portion 18 and becomes connector pin 36b, and till the connector pin 36b from the base end part to the leading section, 2 kinks is arranged, and promptly is bent in a zigzag.At this moment, as shown in figure 10, when 2 place's kinks bend, reversed, between base end part and leading section, turn round and turn 90 degrees.Like this, the plating face of conductor 36 is towards above-below direction at the cardinal extremity face, then is (section is towards above-below direction) towards the side in front end (connector pin 36b) part.In Figure 10, for simplicity, section is represented with hatching.

The principal part of the terminal board 32 of said structure embeds and is installed in the insulator 30 of stator core 17 tops one side, and at this moment, aforementioned 3 pins 34 connect the hole 36a of conductor 36 respectively.And, realize being electrically connected by pin 34 and conductor 36 being carried out soldering in this part.

And the stator core 17 that aforementioned embossed plies 33 will be wound with above-mentioned coil 31 and terminal board 32 is installed is packed in the finishing die 37 (part only is shown among Figure 11), and to inject with PBT be the molten resin postforming of basic material.This embossed plies 33 the centre bore 17a peripheral part about the centre bore 17a in stator core 17 reaches on the both ends of the surface, is molded into all parts roughly cylindric as Fig. 1, shown in Figure 3.Thereby embossed plies 33 integrally covers the principal part except connector portion 18 on the outer peripheral face of stator former iron core 17, coil 31, insulator 30, each pin 34,35, the terminal board 32.

At this moment, as shown in Figure 8, embossed plies 33 is the peripheral part of thin wall shape ground covering stator iron core 17 (the magnetic pole piece 17e of dentate body 17d), the gauge Mw of this thinner wall section be made as dentate body 17d (magnetic pole piece 17e) width dimensions Tw 3～9%.Specifically, the width dimensions Tw of dentate body 17d (magnetic pole piece 17e) is 8.89mm, and the gauge Mw of thinner wall section is 0.35mm.In addition, the bulge size Pw of the protuberance 30d of aforementioned dielectric body 30 is identical with size Mw or smaller.

In addition, as Fig. 1, shown in Figure 3, on this embossed plies 33, a side forms the annular convex 33a corresponding with the concave part 2b of aforementioned housing 2 on stator core 17, forms the 33b of the portion that is stuck (only illustrating 1 among the figure) for aforementioned engaging pawl 2c engaging simultaneously at 3 positions of periphery.On the other hand, embossed plies 33 side below stator core 17 forms and is the cylindric extension and the extension 33c of a side opening below vertically.

At this moment, the outside dimension of this extension 33c is more smaller than that a part of outside dimension of 17 peripheral parts unshakable in one's determination of covering stator in the embossed plies 33, as shown in Figure 1, parting line P occurs at the outer peripheral face (forming the part of ladder) of this extension 33c.In addition, as shown in Figure 3, the peripheral part of the carriage 19 of aforementioned front axle bearing assembly 5 roughly closely is entrenched in the interior perimembranous of this extension 33.

The stator 4 of said structure clips housing 2 and combines with rear bearings assembly 3 as mentioned above, and at this moment, as shown in Figure 3, the concave part 2b of the annular convex 33a of embossed plies 33 and housing 2 is chimeric, locatees and prevents that moisture from invading.Simultaneously, being stuck the 33b of portion engages with the pawl 2c that engages of housing 2.Like this, just the interior perimembranous of stator core 17 and the carriage 19 of rear bearings assembly 3 are fixed, simultaneously that housing 2, rear bearings assembly 3 and stator 4 threes are firmly fixing, and easily exactly to the axle center.

On the other hand, by the chimeric aforementioned bearings assembly 5 of interior perimembranous that the carriage 19 of the interior perimembranous of stator core 17 and aforementioned bearings assembly 5 is fixing, simultaneously that aforementioned bearings assembly 5 is also firmly fixing at the extension 33c of stator 4, and easily exactly to the axle center.And, at this moment the gap size that forms between stator core 17 outer peripheral faces (except that embossed plies 33) and the rotor magnet 28 is set in 0.5～1mm.

Aforementioned embossed plies 33 is by being basic material with PBT, containing and improve a small amount of glass ingredient that intensity uses and added the elastomeric thermoplastic resin of rubber series simultaneously and constitute.By adding rubber series elastomer, can further improve the flowability of melted material, so just can form embossed plies as thin as a wafer at the peripheral part of stator core 17.

In addition, as mentioned above, the difference of embossed plies 33 and insulator 30 and terminal board 32 only is to have or not adds rubber series elastomer and contained glass ingredient amount, all is that the basic material (PBT) with same kind is made.Like this, when carrying out die forming, hot melt is deposited easily to form the resin of embossed plies 33 and the surface of insulator 30 and terminal board 32, cementability between embossed plies 33 and insulator 30 and the terminal board 32 is good, their coefficient of expansion is also identical simultaneously, so embossed plies 33, insulator 30 and terminal board 32 these threes can form an integral body securely.

And, aforementioned finishing die 37 has the cavity corresponding with the profile of embossed plies 33, at this moment as shown in figure 11, the part corresponding in cavity with the peripheral part of stator core 17, each fluting portion (gap between the 17e of adjacent pole portion) that corresponding stator core 17 peripheries occur forms recess 37a.So-called contraction when this recess 37a considers hardening of resin and being provided with.In addition, the inlet 37b that injects resin in cavity is positioned at the mid portion of adjacent dentate body 17d of the fluting portion of a side above the stator core 17.In Fig. 1, show the injection oral area 33d of embossed plies 33.In addition, though not shown, as mentioned above, when being set, finishing die 37 make parting line P be positioned at the extension 33c step portion of embossed plies 33.

When embossed plies 33 was shaped, the stator core 17 that is wound with coil 31 and terminal board 32 has been installed was packed into positioning states in the finishing die 37.At this moment, the protuberance 30d that is located at the 30c of the periphery wall portion lateral surface of aforementioned dielectric body 30 protrudes to the periphery of stator core 17, thus protuberance 30d just with finishing die 37 butt roughly.Under this state, inject molten resin, vacuumize in the cavity with finishing die 37 simultaneously by inlet 37b.

Like this, after in finishing die 37, injecting resin, stator core 17 grades are carried out mold pressing, because of the flowability of molten resin is very high, so also can inject resin effectively at the thin gap portion of stator core 17 peripheral parts with resin.In addition, at this moment by inlet 37b is set in above-mentioned position, make resin easily by between coil 31 adjacent and around to below the end face part of a side, the injection pressure of resin can not directly act on coil 31 simultaneously, can prevent to damage coil 31.And, because the connecting line 31a of coil 31 is positioned at the end difference 30e of the insulator 30 of an opposite side with inlet 37b, so also can prevent to destroy connecting line 31a.

In addition, as mentioned above, because the inner face of the protuberance 30d of insulator 30 and finishing die 37 butt is roughly toppled over distortion so can prevent the 30c of periphery wall portion laterally because of the resin injection pressure.Then, contraction when forming embossed plies 33 owing to the resin hardening by cooling makes the surface of embossed plies 33 produce so-called shrinkage cavity, the recess 37a that forms on the mould 37 but this shrinkage cavity is formed remedies, thereby can form uniform embossed plies 33 at the peripheral part of stator core 17, and resistance to sudden heating is good.And, because parting line P is set in the outer peripheral face of extension 33c, so can prevent harmful effect to resistance to sudden heating etc.

The motor 1 of above structure is used for for example air compressor machine cooling fan of (refrigerating chamber, refrigerating chamber) fan that cool-air feed is used or Machine Room in the case of refrigerator.In this occasion, normally be exposed to for example in-10 ℃ the cold air, perhaps when the defrosting running, be exposed under the high temperature about 30 ℃, promptly in so-called high humidity environment, dewfall, the environment that freezes, use.

On the stator 4 of said structure, almost whole stator core 17, coil 31 except that centre bore 17a, have pin 34 and 35 insulator 30, contain embossed plies 3 integral dies that soldering part all constitutes with thermoplastic resin at the whole base end part of interior terminal board 32, even, also have sufficient rust-proof effect so under high humidity environment, use.Especially, the peripheral part of stator core 17 has also covered with embossed plies 33, so even be not coated with rust inhibitor in addition, also have sufficient rust-proof effect.

In this occasion, can form extremely thin embossed plies 33 at the peripheral part of stator core 17, and can obtain sufficient thermal endurance and resistance to sudden heating.And, by covering, make stator 4 be convenient to operation with embossed plies 33, can improve efficiency of assembling.Also have, self-evident, can protect coil 31, improve insulating properties, improve mechanical strength with embossed plies 33.

But, consider the efficient of motor 1, preferably dwindle the gap between stator core 17 and the rotor magnet 28, be i.e. the thickness of the embossed plies 33 of attenuate stator core 17 peripheral parts as far as possible.By with the material of thermoplastic resin, in fact can form extremely thin embossed plies 33 in addition as embossed plies 33, if but the gauge Mw of the embossed plies 33 of stator core 17 peripheral parts is too small, and can cause resistance to sudden heating to reduce.

For this reason, research according to the inventor, in order to satisfy motor efficiency and resistance to sudden heating both sides' requirement, if embossed plies 33 is decided to be at the gauge Mw of stator core 17 peripheral parts stator core 17 dentate body 17d magnetic pole piece 17e width dimensions Tw 3～9%.Fig. 9 result that to be the inventor test in the relation of the gauge of stator core 17 peripheral parts and resistance to sudden heating (curve A) and motor efficiency (curve B) embossed plies 33.

In this occasion, the transverse axis of Fig. 9 is a ratio (Mw/Tw) of representing the magnetic pole piece 17e width dimensions Tw of the gauge Mw of embossed plies 33 and dentate body 17d with %, in addition, in the acceleration test of resistance to sudden heating, be illustrated in continuously and repeat-30 degree and keep 1 hour, the number of times when 80 degree keep 1 hour loop cycle down till chipping down.From this Fig. 9 as can be known, if embossed plies 33 is set at the gauge Mw of stator core 17 peripheral parts stator core 17 dentate body 17d magnetic pole piece 17e width dimensions Tw 3～9%, then can obtain the high efficiency (more than 40%) of motor, while also can bear about more than 200 times in heatproof impact test, can satisfy motor efficiency and resistance to sudden heating both sides' requirement.

In addition, by the protruding formula connector of aforementioned connector portion's 18 connections, this motor 1 is connected with inverter drive circuit.Here, the leading section of the conductor 36 that is made of the electroplating steel plates that insert in the aforementioned terminal board 32 becomes the connector pin 36b of connector portion 18, and the plate face of this connector pin 36b is turned round and is turn 90 degrees, and the contact-making surface between the protruding formula connector is not section but plating face, causes switching on the bad baneful influence that waits so can prevent that section because of connector pin 36b from getting rusty.

As mentioned above, stator coil is being carried out when resin-molded, the habitual way in past is to use thermosetting resin, perhaps the peripheral part of stator core is not carried out mold pressing, present embodiment is then opposite, is that stator core 17 peripheral parts of 33 pairs of stators 4 of embossed plies of constituting with thermoplastic resin also integrally carry out mold pressing.Like this,, also have sufficient rust-proof effect, needn't apply over requisite rust inhibitor, can simplify manufacturing process even in high humidity environment, dewfall, the environment that freezes, use.And, by the gauge of suitable setting embossed plies 33, can accomplish both had good resistance to sudden heating, can guarantee the efficient that motor 1 is very high again,

Figure 12 represents further embodiment of this invention (corresponding technical scheme 10).Present embodiment is not to form protuberance 30d as above-mentioned embodiment on the 30c of periphery wall portion of insulator 30, but the height dimension a of the 41a of periphery wall portion of insulator 41 is made as below 3 times of gauge b, in other words, is to set gauge bigger.Specifically, be that height dimension a is set at 3mm in this occasion, gauge b is set at 1.5mm.When adopting this structure, the 41a of periphery wall portion has certain thickness, thereby can prevent the distortion that the resin injection pressure causes.

In addition, though it is not shown among the figure, but the inlet 37b that the injection resin of finishing die 37 is used also can not be arranged on the corresponding position of mid portion with the adjacent dentate body 17d of fluting portion, but inlet is positioned at and the facial corresponding position (corresponding technical scheme 6) of going up of terminal board 32 principal parts, like this, the resin injection pressure just directly acts on terminal board 32, can prevent to damage coil 31 effectively.

In addition, the invention is not restricted to the foregoing description, for example the thermoplastic resin material that constitutes embossed plies 33 can use PPS various materials such as (polyphenylene sulfides), in addition, the detailed structure of stator department also can be done all changes, and the purposes of motor also is not limited to the fan motor that refrigerator is used, and can be used for various uses, in a word, can do suitable change without departing from the spirit and scope of the present invention.

As mentioned above, adopt the stator of external-rotor motor of the present invention, because the embossed plies integral die that the base end part of coil and stator core peripheral part and terminal board is constituted with thermoplastic resin, so have sufficient rust-proof effect, and can guarantee the superperformance of motor, simplify manufacturing process simultaneously, have good practical function.

Claims (11)

1. the stator of an external-rotor motor has: stator core; Be wound on the coil in this stator core across insulator; Be located on the described insulator and connect the pin of described end winding; Terminal board, its base end part and described pin are electrically connected, and have and the outside connector portion that is connected usefulness at leading section; Embossed plies, the thermoplastic resin that is carried out integral die by the base end part to the peripheral part of described coil and stator core and terminal board constitutes, on the outer peripheral face of the periphery wall portion of described insulator, be provided with when resin-molded the shaping and the inner face butt of finishing die, can prevent the protuberance that described periphery wall portion is out of shape because of the resin injection pressure.

2. the stator of external-rotor motor according to claim 1 is characterized in that, described insulator and terminal board use the thermoplastic resin that constitutes with the basic material of the same kind of embossed plies to make.

3. the stator of external-rotor motor according to claim 1 and 2 is characterized in that, the thermoplastic resin that constitutes embossed plies adds the elastomer of rubber series in basic material.

4. the stator of external-rotor motor according to claim 1 and 2 is characterized in that, the inlet position of embossed plies is located at the mid portion of the adjacent dentate body of stator core fluting portion.

5. the stator of external-rotor motor according to claim 4 is characterized in that, the connecting line of coil is positioned at the minor diameter end difference that insulator forms at the end face with inlet position opposite one side of stator core on the stator core end face.

6. the stator of external-rotor motor according to claim 1 and 2 is characterized in that, it is facial that going up of terminal board is located in the inlet position of embossed plies.

7. the stator of external-rotor motor according to claim 1 and 2 is characterized in that, embossed plies be set at the gauge of stator core peripheral part this stator core dentation body the magnetic pole piece width dimensions 3～9%.

8. the stator of external-rotor motor according to claim 1 and 2 is characterized in that, by remedy the shrinkage cavity of fluting portion with finishing die, makes the embossed plies of stator core peripheral part form uniform face.

9. the stator of external-rotor motor according to claim 1 and 2 is characterized in that, the outer circumferential surface section of embossed plies prolongs after the end face diameter reduction of stator core vertically, makes parting line be positioned at the outer peripheral face of this extension simultaneously.

10. the stator of external-rotor motor according to claim 1 and 2 is characterized in that, insulator is provided with the periphery wall portion of standing on the coil end periphery integratedly, and the height dimension of this periphery wall portion is set in below 3 times of gauge.

11. the stator of external-rotor motor according to claim 1 and 2 is characterized in that, the conductor that terminal board constitutes by the metallic plate that will have 2 kinks inserts and is shaped, and the plate face of described conductor is turned round at 2 kinks and turn 90 degrees.

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